Apparatus and method for removing objects from forming means

ABSTRACT

An apparatus comprises a forming device for forming objects, a moving arrangement arranged for moving said objects along a path directed from said forming device towards an exit area, passage arrangement for an operating fluid, said passage arrangement being arranged for allowing said objects to be moved towards said exit area at least in a preset portion of said path. A method comprises forming objects, moving said objects along a path directed towards an exit area, and acting on said objects with an operating fluid at least in a preset portion of said path, so as to allow said objects to be moved towards said exit area.

The invention concerns an apparatus and a method for removing objects from forming means, in particular for removing caps made of plastic material from a mould in which they have been formed by means of compression moulding.

U.S. Pat. No. 5,807,592 discloses an apparatus for producing caps provided with a plurality of moulds, each mould comprising a die in which a preset amount of plastic material in a fluid or semifluid state is fed, and further comprising a punch which interacts with the die so as to shape the plastic material in the fluid or semifluid state according to the desired shape of the cap.

When the moulds are opened, a cap remains associated to each punch, the cap being associated to the respective punch near a hollow portion of said cap arranged for engaging with the neck of a bottle.

The caps thus obtained are subsequently removed from the relative punches so as to fall, under the action of gravity, on an underlying circular plate of a transferring carousel.

Here a star-disc, provided with arms that radially protrude from the body of the disc, directs the caps towards an exit area through a path along which the caps are guided by respective side guides.

A drawback of the apparatus disclosed in U.S. Pat. No. 5,807,592 is that the caps falling on the circular plate of the transferring carousel can bounce and subsequently arrange themselves in an undesired position. The possibly bad-positioned caps may prevent the following caps from moving towards the exit area. When this happens, it is necessary to stop the apparatus and to manually remove the caps from the obstruction zone, which implies a loss of productivity.

Another drawback of the apparatus disclosed above is that said apparatus is suitable only for handling caps having a flat surface on a portion of said caps opposite to the hollow portion which engages the bottle neck. In fact the apparatus according to U.S. Pat. No. 5,807,592 is so configured that each cap faces the circular plate of the transferring carousel along the surface that is opposite to the above mentioned hollow portion. In order that the cap may rest on the circular plate thereby achieving a sufficient stable position, the surface that is opposite to the above mentioned hollow portion must have a flat geometry. If said surface is not flat, the cap may swing in relation to the circular plate and reach an undesired position. A further drawback of the apparatus according to U.S. Pat. No. 5,807,592 is due to its quite complicated structure from the constructional and operative point of view, since the above mentioned apparatus requires a relatively high number of mechanical parts, such as for example the star-disc and the guides, which have to be machined and mounted with great precision in order to work properly.

These parts are subjected to breakage or deformation, particularly if one or more non properly positioned caps prevent the following caps from moving towards the exit area, and in the transferring carousel piles of caps are created which exert anomalous stresses on the surrounding mechanical components.

Moreover, the star-disc and the guides constitute bulky parts that make difficult to manually remove the caps from the apparatus when the path towards the exit area is obstructed. Another drawback of the apparatus described above is that it may handle only caps having an axial dimension above a lower limit. If the axial dimension of the caps is smaller than said lower limit, the star-disc acting on the side surface of the caps may collide with mechanical parts, for example guiding parts, protruding upwards from the circular plate or from the exit area.

An object of the invention is to improve the apparatuses and the methods for removing objects from forming means in which said objects have been formed.

A further object of the invention is to reduce the risk of obstructing the path directed towards the exit area of a machine for forming objects.

A still further object is to obtain an apparatus and a method allowing objects having a complicated shape to be handled, for example caps having a flat surface on a portion of said caps opposite to the hollow portion which engages the bottle neck. Another object is to simplify the structure of the apparatuses for forming objects, thereby reducing the number of required mechanical parts and consequently improving construction, mounting, maintenance and operation of such apparatuses.

A further object of the invention is to obtain an apparatus which may process also objects having a very small axial dimension, and in particular low caps.

In a first aspect of the invention, an apparatus is provided comprising forming means for forming objects, moving means arranged for moving said objects along a path directed from said forming means towards an exit area, characterised in that, it further comprises passage means for an operating fluid, said passage means being arranged for allowing said objects to be moved towards said exit area at least in a preset portion of said path.

In a second aspect of the invention, a method is provided comprising forming objects, moving said objects along a path directed towards an exit area, characterised in that, it further comprises acting on said objects with an operating fluid at least in a preset portion of said path, so as to allow said objects to be moved towards said exit area.

The operating fluid, acting on the objects at least in a preset portion of the path directed towards the exit area, simplifies the movement of the objects along said path.

In particular, the operating fluid allows bounces of the objects coming from the forming means to be avoided, thus preventing the objects from reaching an undesired position on the moving means and causing dangerous obstructions. Thus, it is possible to obtain a method and an apparatus having high productivity.

The operating fluid further enables objects having a complicated shape to be processed, for example a non-flat shape.

Finally, owing to the operating fluid it is possible to avoid complex mechanical moving devices, such as the star-disc or the guides disclosed in U.S. Pat. No. 5,807,592. This improves production, operating and maintenance of the apparatus according the invention.

The invention will be better disclosed and carried out with reference to the accompanying drawings, that show some exemplifying and not limiting embodiments thereof, in which:

FIG. 1 is a schematic and interrupted front view of an apparatus for producing caps according to the invention;

FIG. 2 is a top view of moving means of the apparatus shown in FIG. 1;

FIG. 3 is an enlarged and interrupted cross-section taken along the plane III-III of FIG. 1;

FIG. 4 is a detail of a cross-section as the one in FIG. 3, concerning the production of an alternative version of caps;

FIG. 5 is a view as the one in FIG. 1, showing an alternative version of the apparatus according to the invention;

FIG. 6 is an enlarged and interrupted top view of the apparatus of FIG. 5, showing moving means;

FIG. 7 is an enlarged and interrupted cross-section along the plane VII-VII of FIG. 6.

With reference to FIGS. 1 and 2, an apparatus 1 is shown for producing objects made of plastic material, for example caps 2 for bottles, by means of compression moulding. The apparatus 1 comprises forming means 3 provided with a plurality of moulds 4 that may rotate about a vertical axis along a circumference C1, as indicated by the arrow F1 of FIG. 2. Each mould 4 comprises a die 5 provided with a cavity that is shaped according to the external geometry of the cap 2 to be obtained, and a punch arranged above the die 5 and reproducing the internal geometry of the cap 2.

Along the path of each mould 4 along the circumference C1, it is possible to identify a mould feeding step in which a preset amount of plastic material in a fluid or semifluid state is fed in each die 5, a forming and stabilizing step for forming and stabilizing the cap 2 in the mould 4, and an unloading step in which the just formed cap 2 is extracted from the mould 4.

During the forming and stabilizing step, the die 5 and the punch are arranged in a closed configuration in which they mutually cooperate for shaping the plastic material according to the desired geometry of the cap 2. On the contrary, in the mould feeding step and in the unloading step the die 5 and the punch are arranged in an open configuration, in which they are at a certain mutual distance so as to allow the plastic material to be introduced into the mould 4 and the just formed cap 2 to be removed from the mould 4.

In particular, the mould feeding step and the unloading step occur substantially simultaneously because, while the just formed cap 2 is removed from the punch, a dose of plastic material in a fluid or semifluid state is fed into the underlying die 5. This takes place when the mould is in the first position P indicated in FIGS. 1 and 2.

At the end of the forming step, the cap 2 is removed from the punch, for example by exerting an extraction pressure, and delivered to moving means arranged for moving each cap 2 towards an exit area of the apparatus 1.

The moving means comprises a transferring wheel 6 which may rotate about a first vertical axis Z and on which each cap 2 falls from the above punch, under the effect of gravity.

As shown in detail in FIG. 3, the transferring wheel 6 comprises a ring 7 suitable for receiving the end surface of the caps 2 that is opposite to the hollow portion of said caps in which the bottle neck has to be inserted. The ring 7 is fixed to a circular plate 8 that is in turn connected, by means of a lid 9, to the end of a shaft 10 extending along the first axis Z. The shaft 10 is rotatably supported by bearings 11 and it is rotated by means of a gear 12, which is in turn operated by means of a further gear 13 that is rotated by means of a belt 14, as shown in FIG. 1.

At the lower surface of the circular plate 8 a plurality of cups 15 is fixed. Each cup 15 can comprise, for example, a member having a U-shaped section taken along a plane orthogonal to the first axis Z. The cup 15 can have any other different shape that is suitable for receiving the plastic material which will form the caps 2.

The cups 15 rotate together with the circular plate 8 and define a circular path along which they interact with an extruder, not shown, provided with an upwards directed mouth from which plastic material in a fluid or semifluid state exits. When a cup 15 passes above the extruder, it takes away from the latter a prefixed amount of plastic material which, due to its pasty consistency, adheres to the walls of the cup 15. When the cup 15, during its movement along the circular path around the first axis Z, reaches the first position P above an empty die 5, a compressed air blast detaches the plastic material from the above mentioned cup and causes the plastic material to fall in the underlying die 5. The compressed air is sent to each cup by means of a passage 16 obtained in the circular plate 8 and communicating with the external environment by means of a plurality of further passages 17 obtained in an upper portion of the cup 15.

First suction means is associated to the transferring wheel 6, said first suction means comprising a plurality of radial conduits 18 obtained in the thickness of the circular plate 8, and communicating with the external environment by means of respective through holes 19 vertically extending through the circular plate 8 and the ring 7. On the upper surface of the ring 7, at each through hole 19, a spot-facing 20 can be provided, said spot-facing being arranged for receiving the end surface of a cap 2 that is opposite to the hollow portion of the same cap.

The radial conduits 18 may be selectively connected to a vacuum pump, not shown, by means of a distributor 22, that is shown in FIGS. 2 and 3. The distributor 22 has an annular shape and is provided with a slot 23 extending along the distributor 22 for an angular extension that is slightly greater than 90°. The distributor 22 is fixed to the lower surface of an annular element 24 housed in a groove 25 obtained in a further annular element 26. The latter is arranged in a fixed position on the apparatus 1 and supports the external rings of two further bearings 27, on which the lid 9 is mounted. Thus the lid 9, fixed to the shaft 10 by means of a spline 28, may rotate in relation to the annular element 24, to the further annular element 26 and to the distributor 22, thereby dragging in rotation the circular plate 8 and the ring 7.

A pneumatic connector 21, connected to the annular element 24 and to the further annular element 26, enables the distributor 22 to be connected to the vacuum pump.

When the circular plate 8 and the ring 7, which is fixed to said circular plate, rotate about the first axis Z in the direction of the arrow F2 shown in FIG. 2, the distributor 22 connects the radial conduits 18 to the vacuum pump along a suction section A, which is hatched in FIG. 2 and has an angular length slightly greater than 90°. In particular, each radial conduit 18 is connected to the vacuum pump just before the relative spot-facing 20 reaches the first position P, and it is isolated from this pump near a second position Q in which the transferring wheel 6 interacts with an evacuation wheel 29 arranged for transporting the caps 2 towards an exit area of the apparatus 1.

When, in the first position P, a cap 2 which has been removed from the relative punch falls under gravity onto the transferring wheel 6, said cap is kept adherent to the ring 7 near the respective spot-facing 20, owing to the suction acting along the section A.

The cap 2, firmly associated to the ring 7 by means of suction, is moved together with the transferring wheel 6 for an angular distance of about 90°, until said cap reaches the second position Q in which it is collected by the evacuation wheel 29. The latter may rotate about a second axis Y, parallel to the first axis Z and therefore vertical, in a rotation direction opposite to the rotation direction of the transferring wheel 6, as indicated by the arrow F3 of FIG. 2. The evacuation wheel 29 is arranged at the upper end of a vertical support 34 fixed to a frame of the apparatus 1. A non-shown shaft extends inside the vertical support 34, said shaft enabling the evacuation wheel 29 to rotate owing to known driving means. The driving means that actuates the evacuation wheel 29 may also move the belt 14, by means of which movement is transmitted to the transferring wheel 6.

The evacuation wheel 29 comprises a star-disc 30 provided with a plurality of radial arms 31, each radial arm being provided with a front edge 32 arranged for interacting with a cap 2 in order to remove said cap from the transferring wheel 6 and direct said cap along an arc-shaped transfer plane 33.

The evacuation wheel 29 interacts with the transferring wheel 6 near the second position Q, in which the suction section A on the transferring wheel 6 ends. In such position, the cap 2 is merely resting on the ring 7, no additional force maintaining the cap 2 in contact with the above mentioned ring. The corresponding radial arm 31 of the star-disc 30 may therefore easily remove the cap 2 from the transferring wheel 6 by means of mechanical action and direct said cap along the arc-shaped transfer plane 33 until the cap 2 reaches a belt conveyor 35 that conveys each cap 2 towards the exit of the apparatus 1 in the direction of the arrow F4.

In the embodiment of FIG. 2, the star-disc 30 is provided with eight radial arms 31, corresponding to the eight spot-facings 20 and to the eight radial conduits 18 of the transfer wheel 6. Nevertheless, according to the machine type and to the desired speed, it is possible to provide a different number of radial arms 31, of spot-facings 20 and of radial conduits 18. The apparatus 1 further comprises a S-shaped guide 37 arranged for guiding the caps 2 in their path towards the belt conveyor 35. The guide 37 is fixed to a central zone of the transferring wheel 6 and it is provided with an end extending along the arc-shaped transfer plane 33.

The first suction means, associated with the upper surface of the transferring wheel 6, enables the caps 2 to be kept adherent to the ring 7 during their path towards the evacuation wheel 29. In particular, when each cap 2 is removed from the corresponding punch, the first suction means exerts on such cap an attractive force directed towards the transferring wheel 6, said attractive force making easier removing the cap 2 from the punch.

Furthermore, owing to the first suction means it is possible to prevent the caps 2 from bouncing on the transferring wheel 6 when falling from the upper punch. Thus, the risk of jams in the apparatus 1 due to an incorrect positioning of the caps 2 which bounce on the transferring wheel 6 is strongly reduced. The first suction means also assures that the caps 2 remain in the correct position on the transferring wheel 6 during their path towards the evacuation wheel 29.

It is to be noted that the transferring wheel 6 and the evacuation wheel 29 can handle caps 2 having mutually different dimensions and/or shapes without requiring size parts to be replaced. In fact, suction occurring over the spot-facings 20 enables caps 2 having different sizes to be kept adherent to the transferring wheel 6. This allows the re-equipment time of the apparatus 1 to be reduced, said re-equipment time being necessary for enabling such apparatus to pass from production of caps 2 of a specific dimensional range to production of caps 2 of a further dimensional range.

As shown in detail in FIG. 4, the apparatus according to the invention is suitable for handling objects, for example caps, having a quite complex shape. In the case in point, it is shown a cap 2′ having a convex surface 38 delimiting the cap 2′ in its end portion that is opposite to the hollow portion suitable for engaging with the bottle neck.

The cap 2′ can be easily kept adherent to the transferring wheel 6 by means of the first suction means, by merely providing the ring 7 with a plurality of seats 50 having a shape corresponding to the geometry of the cap 2′. The seats 50 communicate with the radial conduits 18 through the holes 19 and can be provided with respective spot-facings 20.

When the cap 2′ is removed from the punch, said cap falls onto a seat 50 and shapingly engages with said seat. Owing to suction exerted through the radial conduits 18, the cap 2′ is prevented from leaving the seat 50.

With reference to FIGS. 5 to 7, an alternative embodiment of the apparatus 1 is shown, said alternative embodiment differing from the embodiment of FIGS. 1 to 3 for the structure of the evacuation wheel 29. The forming means 3 and the transferring wheel 6 have a structure similar to that previously described. The evacuation wheel 29 according to FIGS. 5 to 7 comprises a disc 38 fixed to a further lid 39 coupled to a further shaft 40 by means of a further spline 41. The further shaft 40 extends along the second axis Y inside the vertical support 34 and it is operated by known driving means.

Second suction means is associated with the evacuation wheel 29, said second suction means comprising a plurality of further radial conduits 42 obtained in the thickness of the disc 38 and ending at further through holes 43 arranged in exit areas on the lower surface of the disc 38. Around each further through hole 43 a further spot-facing 44 can be provided, said further spot-facing 44 being obtained on the lower surface of the disc 38.

The further radial conduits 42 can be connected to a suction source through a further distributor 45 comprising a body having an annular shape that is positioned under the disc 38. The further distributor 45 is provided with a further through slot 46 extending along an angle of about 120° and is fixed to a support member 47 mounted around the further shaft 40, with interposition of a bushing 48. The support member 47 is further connected to a plate 49 fixed to the vertical support 34. Therefore, when the disc 38 rotates the further distributor 45 remains in a fixed position on the apparatus 1.

Each exit area arranged around the further through hole 43 of the disc 38 communicates with the suction source along a portion of the path around the second axis Y that corresponds to a further suction section A′, hatched in FIG. 6. More in particular, by means of the further distributor 45 each exit area is connected to the suction source when the evacuation wheel 29 interacts with the transferring wheel 6 in the second position Q, and is isolated from the suction source in a third position R in which the exit area is over the belt conveyor 35. In operation, in the second position Q each cap 2, initially arranged on the transferring wheel 6, is collected by the evacuation wheel 29 by means of suction exerted through the further through holes 43. The cap 2, which is no more retained on the transferring wheel 6 by suction because suction ends near the second position Q, adheres to the lower surface of the disc 38 at the end surface of the cap arranged for engaging with the bottle neck and is moved together with such disc until it reaches the third position R. In this position, suction through the further conduits 42 ends and the cap 2 stops adhering to the disc 38, thereby falling by gravity on the underlying belt conveyor 35.

The disc 38 provided with second suction means may replace the star-disc 30, which allows the structure of the evacuation wheel 29 to be significantly simplified. In fact, it is no more necessary to provide a plurality of radial arms having large overall dimensions and causing a complicated access to the evacuation wheel 29. Furthermore, pneumatically transporting the caps 2 enables the risks of damaging the caps 2 during transport to be reduced. On the other hand, such risks are quite high in case of transport by means of mechanical elements pushing the caps 2 along the desired path.

Owing to the second suction means, the evacuation wheel 29 further allows caps 2 having different dimensions and/or shape to be transported, without replacing size parts.

Furthermore the evacuation wheel 29 is suitable for processing caps 2 having also irregular shapes, in particular caps delimited by a non-flat surface on the portion of said caps opposite to the hollow portion arranged for engaging with the bottle neck.

Owing to the second suction means the apparatus 1 may furthermore handle very low caps, i.e. caps having a particularly small axial dimension that cannot be processed by the known star-discs. In fact, the evacuating wheel 29 associated with the second suction means is not provided with mechanical parts which, while acting on the side surface of the caps 2, could bump against other parts of the apparatus. The second suction means allows the evacuating wheel 29 to act only on the hollow portion of the caps 2, thereby preventing any collision against adjacent parts.

It is to be noted that the evacuation wheel 29 provided with the second suction means can be used also in combination with a transferring wheel 6 of the known type, i.e. without first suction means.

The apparatus 1 disclosed above can be used not only for processing caps 2, but also for processing other kinds of objects, for example cups, items provided with an axial symmetry, or in general articles that can be obtained by moulding. 

1-29. (canceled)
 30. Apparatus comprising a forming device for compression moulding of objects, a moving wheel arrangement arranged for moving said objects along a path extending from said forming device to an exit zone, and further comprising a passage arrangement through which an operating fluid is conveyable, wherein said passage arrangement passes through a plate portion of said moving wheel arrangement and leads out on said moving wheel arrangement in an intended collecting region of said objects for keeping said objects adherent to said plate portion at least along a preset portion of said path.
 31. Apparatus according to claim 30, wherein said passage arrangement is included in a suction device arranged for keeping said objects associated with said moving wheel arrangement along said preset portion.
 32. Apparatus according to claim 31, wherein said suction device comprises a distributor element arranged for selectively connecting said passage arrangement with a suction source.
 33. Apparatus according to claim 32, wherein said passage arrangement is obtained in a disc of said moving wheel arrangement, said disc being rotatably movable in relation to said distributor element around a preset axis.
 34. Apparatus according to claim 33, wherein said distributor element is provided with a slot communicating with said suction source.
 35. Apparatus according to claim 34, wherein said slot extends along a circular section arranged around said preset axis.
 36. Apparatus according to claim 35, wherein said passage arrangement is provided with an end facing said distributor element at a distance from said preset axis that is substantially equal to a radius of said circular section.
 37. Apparatus according to claim 33, wherein said passage arrangement comprises at least one conduit radially extending through said disc.
 38. Apparatus according to claim 37, wherein said at least one conduit is included in a plurality of conduits which are angularly equidistant on said disc.
 39. Apparatus according to claim 31, wherein said moving wheel arrangement comprises a transferring wheel arranged for receiving said objects from said forming device.
 40. Apparatus according to claim 39, wherein said moving wheel arrangement comprises an evacuation wheel arranged for transferring said objects from said transferring wheel arrangement to said exit zone.
 41. Apparatus according to claim 40, wherein said suction device comprises a first suction device arranged for keeping said objects associated with said transferring wheel along a suction section comprised between a collecting position of said objects from said forming device and a delivering position of said objects to said evacuation wheel.
 42. Apparatus according to claim 41, wherein said first suction device is so configured as to keep said objects associated with an upper surface of said transferring wheel.
 43. Apparatus according to claim 40, wherein said evacuation wheel comprises a star-disc provided with a plurality of radial arms arranged for pushing said objects from said transferring wheel to said exit zone.
 44. Apparatus according to claim 41, wherein said suction device comprises a second suction device arranged for keeping said objects associated with said evacuation wheel.
 45. Apparatus according to claim 44, wherein said second suction device is associated to a surface of said evacuation wheel that is opposite to a further surface of said transferring wheel with which said first suction device is associated.
 46. Apparatus according to claim 44, wherein said second suction device is associated with said evacuation wheel along a further suction section comprised between said delivering position and said exit zone.
 47. Apparatus according to claim 40, wherein in said exit zone a conveyor device is provided, said conveyor device being arranged for removing said objects from said evacuation wheel.
 48. Apparatus according to claim 39, wherein said transferring wheel is located below a punch of said forming device.
 49. Apparatus according to claim 30, and further comprising at least one spot-facing at which a passage of said passage arrangement ends on an external surface of a wheel of said moving wheel arrangement.
 50. Apparatus according to claim 30, wherein at least one passage of said passage arrangement ends on at least one wheel of said moving wheel arrangement near a seat shaped according to the shape of a portion of said objects intended to interact with said at least one wheel.
 51. Method comprising compression moulding objects, moving said objects along a path extending to an exit zone by using a moving wheel arrangement, wherein during said moving said objects are kept adherent to a plate portion of said moving wheel arrangement by an operating fluid conveyed through a passage arrangement passing through said plate portion, at least along a preset portion of said path.
 52. Method according to claim 51, wherein said moving comprises exerting on said objects a suction force, suitable for associating said objects with a moving surface of said moving wheel arrangement.
 53. Method according to claim 52, wherein said moving comprises keeping said objects associated with said moving surface along said preset portion, by means of said suction force.
 54. Method according to claim 53, wherein said keeping comprises transporting said objects from a collecting position of said objects, that have been just formed, to a delivering position towards said exit zone.
 55. Method according to claim 54, wherein, after said compression moulding, said objects fall in said collecting position.
 56. Method according to claim 54, wherein, after said transporting, it is provided mechanically pushing said objects from said delivering position to said exit zone.
 57. Method according to claim 54, wherein said moving comprises further transporting said objects from said delivering position to said exit zone.
 58. Method according to claim 57, wherein, during said transporting, it is provided sucking on a surface of said objects, said surface being opposite to a further surface of said objects on which further sucking is provided during said further transporting. 